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S&OP Manager
provides an integrated software solution to calculate &
maintain supply chain levels as your business sales mix and
volume changes. S&OP Manager imports
data from your current MRP/ERP software, and exports newly
calculated data back to your MRP/ERP software. This process
allows you to utilize the processing power of your current
software to manage electronic and or visual supply chain levels,
while maintaining data integrity and an integrated database
structure.
The entire purpose of the S&OP Manager
process and software is to easily calculate & forecast
the supply chain levels required at suppliers, and your manufacturing
locations to facilitate an assemble to order business, with
a high on time delivery to the customer date, and a high inventory
turn ratio.
The complexity of managing a data base of history, customer
forecasts, bills of material, routings, capacity, inventory
levels, for the purpose of predicting a forecast that populates
the supply chain with the required materials in the conventional
sense is overwhelming at best. When the complexity of hundreds
and even thousands of saleable SKU's is considered, a forecast
is complex, and in many cases not accomplished.
S&OP Manager eliminates the complexity
of managing the database supply chain. The major elements
of S&OP Manager are;
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1. The development
of sales planning families—these forecasted items
are reduced from hundreds to tens of items,
making forecast development simplified.. .one assignment
reduced the complexity from 15,000 to less
than 100 items;
2. Software ability to generate a forecast
from history with consideration of specific months to
use as history, % family change
to forecast and many other features;
3. Export of planning family forecast back
to your MRP/ERP software for use in;
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Providing suppliers with 1 line planning visibility;
• Establishing/maintaining kanban and other inventory
levels;
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Capacity planning of Lean cells;
• Output of Order management available to promise for
the purpose of
scheduling customer orders at
the time of order entry; The PPQ process—this
process is utilized to establish
the product family process maps best suitable for development
of cells—this utility is generally
only run once during the development of a "Lean"
implementation;
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| S&OP Manager Information/Data
Flowchart |
S&OP
Manager, is an information flow process that is the
foundation for a successful Sales & Operations Planning
process.
The process steps are export data from MRP/ERP to S&OP
Manager, develop a forecast, review cell capacity,
financial plan, and export forecast to MRP/ERP, and to ATP Manager
This process is repeated monthly to coincide with the financial
planning cycle, and is is also done each time the business experiences
or plans a significant change in business. |
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| S&OP Manager Information/Data
Flowchart |
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| Sales & Operations
Planning Inputs required for S&OP |
•
Planning family history is extracted from MRP/ERP by
family,
• The Master Scheduler develops a forecast
using the history and any market intelligence that may
be available, the forecast is
by planning family, and not for each item sold, however
the information regarding a
saleable item is readily available. The goal is to forecast
at the family level and stock at the component level
for final assembly, and at lower levels for supply of
product to the final assembly cells,
• The master Scheduler seeks sales & engineering
input regarding changes in the market place, such as
those described above,
• The forecast is calculated and electronically distributed
to the S&OP planning team for review prior to the
S&OP team review,
• A video/teleconference S&OP review is conducted
with team participation,
• When agreement on the forecast by planning family is
reached, the forecast comprised of planning family member
percentages are exported to the MRP/ERP software for forecasting, |
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| Outputs of S&OP |
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When your MRP/ERP has been processed and calculated,
the forecasted usage for each kanban part is used
to calculate kanban quantities,
• A supplier 1 line per MRP item purchased
part is sent to each supplier for planning purposes,
• The final assembly cell capacity for planning
family is updated in the ATC cell scheduling software,
which resides at order entry
on the MRP/ERP software.
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05.05.06
